PDL

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED.
They are merely loaned on the borrower's express agreement that

they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
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WELDING SPECIFICATION
FOR
MAIN LINE
FOR
TRANSPORTATION OF GAS
0 23.03.06 ISSUED FOR BIDS

REV. DATE REVISIONS BY CHECKED APPROVED
SPECIFICATION REV.
WELDING SPECIFICATION FOR
ENGINEERS INDIA LIMITED MAIN LINE FOR TRANSPORTATION
NEW DELHI
0318-6-77-0009 0
OF GAS
Page 1 of 53
EIL-1641-1251 REV.2 A4-210x297
CONTENTS
1.0 SCOPE
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
2.0 APPLICABLE CODES AND STANDARDS

3.0 BASE MATERIAL
4.0 WELDING CONSUMABLES
5.0 EQUIPMENT & ACCESSORIES
6.0 WELDING PROCESSES
7.0 BEVEL CLEANING AND BEVEL INSPECTION
8.0 ALIGNMENT AND SPACING
9.0 WEATHER CONDITIONS
10.0 WELDING
11.0 HEAT TREATMENT
12.0 INSPECTION AND TESTING
13.0 REPAIR OF WELDS
ANNEXURE – 1 : DESTRUCTIVE TESTING
ANNEXURE – 2 : ULTRASONIC INSPECTION
ANNEXURE – 2 : AUTOMATIC ULTRASONIC TESTING
ANNEXURE – 4 : RADIOGRAPHY
EXHIBIT-A : ELECTRODE QUALIFICATION TEST RECORD
EXHIBIT-B : STRESS RELIEF HEAT TREATMENT PROCEDURE

SPECIFICATION
EXHIBIT-C : WELDING PROCEDURE QUALIFICATION TEST

RECORD
EXHIBIT-D : WELDER QUALIFICATION TEST RECORD
EXHIBIT-E : WELDERS IDENTIFICATION CARD
EXHIBIT-F : RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
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1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of
welded joints of carbon steel piping systems connected with the pipeline and related
facilities.
The welded pipe joints shall include the following:
a) All line pipe joints of the longitudinal and circumferential butt-welded and
socket welded types.
b) Attachments of castings, forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded / fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other
instrument tappings.
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
2.0 APPLICABLE CODE AND STANDARDS
All welding work, equipment for welding, heat treatment, other auxiliary functions and
the welding personnel shall meet the requirements of the latest editions of the codes,
standards and specifications listed below:
a) Code for Gas Transmission and Distribution Piping Systems,

ANSI B 31.8.
b) Standard for welding of Pipelines and Related Facilities, API 1104.
c) Specification for welding Electrodes and Filler Materials ASME Sec. II C.
d) Non Destructive examination, ASME Sec. V.
3.0 BASE MATERIAL
a) In general carbon steel is used in this specification. The details of material

specifications are given in the welding Specification Chart attached along with
other project data sheets. The CONTRACTOR will arrange and maintain the
record of test certificates of all the materials for the reference of the welding
engineer.
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4.0 WELDING CONSUMABLES
a) The CONTRACTOR shall provide at his own expense all the welding
consumables necessary for the execution of the job such as electrodes, oxygen,
acetylene etc. and these shall bear the approval of the COMPANY.
b) The welding electrodes / filler wires supplied by the CONTRACTOR shall

conform to the class specified in the welding specification chart attached along
with other project data sheets. The materials shall be of the make approved by
the COMPANY.
c) The electrode shall suitable for the welding process recommended and the base
metal used. Physical properties of the welds produced by an electrode/ filler
wire recommended for the welding of a particular base metal shall not be lower
than the minimum values specified for the base metal unless otherwise specified
in the Welding Specification Chart and shall correspond to the physical
properties of the class of electrode/ filler wire adopted. The choice of electrode
shall be made after conducting the required tests on the electrodes/ filler wire as
per relevant standards, and shall be the sole prerogative of the COMPANY.
d) The CONTRACTOR shall submit batch test certificates from each electrode/
filler wire manufacturers giving details of physical and chemical tests carried
out by them for each batch of electrodes to be used.
e) Electrode/ filler metal Qualification test records shall be submitted as per the
Exhibit–A (attached) in respect of the electrodes/ filler metal tested by the
CONTRACTOR for obtaining the approval of the COMPANY.
f) All electrodes/ filler wire shall be purchased in sealed containers and stored
properly to prevent deterioration. The electrodes removed from the containers
(except cellulosic coated electrodes) shall be kept in the holding ovens, at the
temperature recommended by the electrode manufacturer. Ovens shall be used
for the low hydrogen electrodes only. Out-of-the oven time of electrodes before
they are consumed shall not exceed the limits recommended by the electrode
manufacturer. The electrodes shall be handled with care to avoid the any
damage to the flux covering. Different grades of electrodes shall be stored
separately. Cellulosic electrodes used shall however be used as per the specific
recommendations of manufacturer.
g) The electrodes used shall be free from rust, oil, grease, earth and other foreign
matter, which affect the quality of welding.
h) Shielding Gas
The composition and the purity of shielding the gas when required by the
welding processes other than shielded metal arc welding, COMPANY shall bear
the approval of the COMPANY. Wherever appropriate, gases or gas mixture of
the following quality shall be used.
1. Argon gas complying with BS 4365.
2. Carbon dioxide gas complying with type 1 specified in BS 4105

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3. Gas mixtures that have been proved to be satisfactory as a result of
procedure approval tests.
When a gas mixture is used, which has specified additions, e.g. 2% O2, 5% CO2
the variation of such addition shall not exceed +10% of that stated. Moisture
content shall correspond to a dew point of -300 C or lower.
5.0 EQUIPMENT & ACCESSORIES
The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedules.
5.1 All the equipment for performing the heat treatment, including transformers,
thermocouples, pyro-meters, automatic temperature recorders with suitable calibration
arrangements, etc. shall be provided by the CONTRACTOR, at his own expense and
these shall bear the approval of the COMPANY. Adequate means of measuring current
and voltage shall be available.
5.2 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR, will be done at his own expense.
6.0 WELDING PROCESSES
6.1 Welding of various materials under this specification shall be carried out using the
following process.
6.1.1 MAIN LINE (PART-A, SPREAD I & II, CH. 0.00KM TO CH.113KM):
AUTOMATIC GAS METAL ARC WELDING FROM BOTH SIDES OR WELDING

FROM OUTSIDE ONLY WITH COPPER BACKING. NON DESTRUCTIVE
EXAMINATION SHALL BE CARRIED OUT AS PER REQUIERMENTS OF
SECTION 12.5.
6.1.2 MAIN LINE (PART-B, SPREADS III &IV, CH. 113KM TO CH. 187KM)
(HILLY AREAS/ROCKY TERRAIN):
1. AUTOMATIC GAS METAL ARC WELDING FROM BOTH SIDES OR

WELDING FROM OUTSIDE ONLY WITH COPPER BACKING
2.a) SEMIAUTOMATIC GMAW WITH SPECIAL CONTROLLED PULSED

WAVE FORM CAPABLE OF MAKING ROOT RUNS FOR ROOT RUN
2.b) SEMIAUTOMATIC GMAW/ FCAW FOR FILL AND CAP RUNS
6.1.3 TIE –INS AND CROSSINGS: ANY OF THE PROCESSES SPECIFIED

ABOVE AS PER QUALIFIED PROCEDURES
6.1.4 DOUBLE JOINTING OF TWO PIPE LENGTHS USING SUBMERGED ARC

WELDING IN SPECIALLY LAID PIPE WELDING YARD IS ALSO PERMITTED
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Any deviation desired by the CONTRACTOR shall be obtained through the express
consent of the COMPANY.
Following agencies for Automatic welding Systems are acceptable:

a) CRC-Evans Automatic Welding Systems, Houston

b) Pipe Welding Technology, Italy

c) RMS Welding Systems, Canada
d) Sermier Dasa, France
In case bidder proposes to employ any other agency, the proposed agency shall meet
the qualification criteria listed below and shall submit necessary documentation to
establish meeting the criteria. The detailed system description and procedure shall be
submitted for company evaluation/ approval
Automatic welding systems and agencies who have proven track record of high
productivity and satisfactory quality and have done a single project of diameter 36” or
above and minimum length of 50 km and also have welded a cumulative length of 500
km or above on large diameter Pipe lines, in the last ten years only shall be accepted.
Contractor shall employ only such automatic welding systems for the work covered by
main line automatic welding. The track record shall be submitted to the company for
approval prior to engagement.
6.2 The welding procedure adopted and the consumables used shall be specifically
approved.
6.3 A combination of different welding processes or a combination of electrodes of

different classes / makes could be employed for a particular joint only after duly
qualifying the welding procedures to be adopted and obtaining the approval of the
COMPANY.
7.0 BEVEL CLEANING / BEVEL INSPECTION
The Line Pipe supplied by COMPANY shall have bevel ends as specified in the
applicable specification for the Line Pipe attached with the Bid Package. Any
modification thereto, if required by the CONTRACTOR due to his special welding
technique, shall be carried out by the CONTRACTOR at his own cost. Before welding,
all the rust and the foreign matter shall be removed from the bevelled ends by power
operated tools. This shall be effected inside and outside and for a minimum distance of
25 mm from the edge of the weld bevel. The bevels shall be thoroughly inspected at
this stage. If any of the ends of the pipe joints are damaged to the extent that, in the
opinion of the COMPANY, satisfactory weld spacing cannot be obtained and local
repair by grinding cannot be successfully done, the damaged ends shall be cut and
bevelled to the satisfaction of the COMPANY, with an approved bevelling machine.
Manual cutting and weld repairs of bevels is not allowed. Should laminations, split
ends or inherent manufacturing defects in the pipe be discovered, the lengths of pipe
containing such defects shall be removed from the line to the satisfaction of
COMPANY. On pipes, which have been cut back, the new bevel shall be 100% visual
and 100% dye penetrant/MPI tested. A report shall be written for all the testing and
records kept.
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8.0 ALIGNMENT AND SPACING
Immediately prior to line-up CONTRACTOR shall inspect the pipe ends inside and
outside for damage, dents, laminations etc. Pipe for welding shall be set up, correctly
spaced, allowing for the temperature changes during welding. In correct alignment shall
in no circumstances be sprung into position. Temporary attachments of any kind shall

not be welded to the pipe. Welds joining the sections of the pipeline, valve installation
or similar welds classified as tie-in welds shall be made in the trench. Otherwise the
alignment and welding shall be made alongside the ditch with the pipe supported on
skids and pack pads or other suitable means approved by COMPANY, at least 500 mm
above the ground unless approved by the COMPANY in specific cases.
Seam orientation of welded pipe shall be selected to ensure that at the circumferential
welds, the longitudinal welds shall be staggered in the top 900 of the pipeline, or 250
mm whichever is the lesser. A longitudinal joint shall pass an appurtenance of a
structural element at a minimum distance of 50 mm. Should a section of the line
containing uncompleted welds fall from the skids, the CONTRACTOR shall
immediately inform the COMPANY.
Every effort shall be made to reduce misalignment by the use of the clamp and rotation
of the pipes to the best fit. For pipe of same nominal wall thickness the offset shall not
exceed 1.6 mm. The off set may be checked from outside using dial guages. Any
branch connection sleeve, etc. shall be at least 150 mm from any other weld. The welds
for fittings shall be so located that the toe of the weld shall not come within 50 mm of
any other weld. Cold dressing is permissible only in cases of slight misalignment and
may only be carried out with a bronze headed hammer. Hot dressing shall not be
permitted. When welding pipes of different wall thickness (as directed by COMPANY)
a special transition piece shall be used. This shall have a minimum of 1:4 taper. The
welds shall be subject to both ultrasonic and radiographic inspection.
The root gap shall be accurately checked and shall conform to the qualified welding
procedure. The use of internal Line-up Clamps is mandatory for pipe diameters 10”
and above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe 10”
etc.) where it is impossible to use internal clamps, an external line-up clamp may be
used.
The internal line-up clamp shall not be released before the entire first pass has been
completed.
When an external line-up clamp is used, all the spaces between the bars or at least 60%
of the first pass shall be welded before the clamp is released and the pipe remaining
adequately supported on each side of the joint.
Segments thus welded shall be equally spaced around the circumference of the pipe.
Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
9.0 WEATHER CONDITIONS
The parts being welded and the welding personnel shall be adequately protected from
rain and strong winds. In the absence of such a protection no welding shall be carried
out. The completed welds shall be suitably protected in case of bad weather conditions.
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10.0 WELDING
10.1 Root Pass

a) The root pass shall be made with the electrodes/filler wires recommended in the
welding specification chart attached along with the other project data sheets.
The size of the electrodes used shall be as per the approved welding procedure.
b) Position or roll welding may be permitted. Separate procedures shall be

submitted and qualified for up hill, down hill, vertical down and roll welding.
The vertical up method of welding shall be used for the root pass of the tie-ins,
special crossings, fittings and special parts, fillet welds, repairs and when an
external line up clamp is used. The down hill welding may be used for the root
run welding of tie-ins and special crossings when (a) the edges are machined or
have equivalent preparation (b) line up clamps are used and the fit up is
geometrically and mechanically similar to one of the ordinary line welding
without misalignment or unevenness.
c) The root pass of butt joints shall be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
pipe shall not exceed 3 mm wherever not specified by the applicable code.
d) Any deviations desired from the recommended welding technique and

electrodes indicated in the welding specification chart shall be adopted only
after obtaining express approval of the COMPANY.
e) Welding shall be continuous and uninterrupted during a pass.
f) On completion of each run, craters, welding irregularities, slag etc., shall be

removed by grinding and chiseling.
g) While the welding is in progress care shall be taken to avoid any kind of
movement of the components, shocks, vibration and stresses to prevent
occurrence of weld cracks.
h) Fillet welds shall be made by shielded metal arc welding process irrespective of
the thickness and class of piping. Electrode size shall not exceed 3.25 mm
diameter for the socket joints. At least two passes shall be made on the socket
weld joints.
i) Peening shall not be used.
10.2 Joint completion
The first pass shall be carried out by a minimum of two welders/ welding heads,
working simultaneously and so placed as to cause minimum distortion of the pipe.
The number of welders/ welding heads and the allowable welding sequences shall be as
those laid down in the qualified welding procedure specification. Once the deposit of
the first pass has been started, it must be completed as rapidly as possible, reducing
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interruptions to the minimum. The welding and wire speed shall be approximately
same as that established in the qualified welding procedure specification.
The pipe shall always be adequately supported and must not be bumped or shaken
during welding. The clamp shall be removed, as indicated in clause 8.0 above. Before
starting the second pass, the first pass shall be cleaned and flattened with rotating
grinders.
The interruption between completion of the first pass and starting the second pass shall
be as stated in the procedure specification as per the qualified welding procedures.
The welding speed selected shall enable production of a bead which is sufficiently thick
and which shows no under cutting.
The time lapse between the second and the third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or
following passes, welding operations may be suspended, so allowing the joint to cool
down, provided that the thickness of the weld metal deposited is equal to at least 50%
of the pipe thickness. Upon restarting, depending on the materials, wall thickness and
welding process, a preheating of at least 1000 C shall be applied. Subsequent passes up
to weld completion shall be protected to avoid rapid cooling, if meteorological
conditions so dictate. Cleaning between the passes shall be done carefully so as to
reduce the possibility of inclusions.
The electrode starting and finishing points shall be staggered from pass to pass. Arc-
strikes outside the bevel on the pipe surface are not permitted. Arc-strike or arc-burn
on the pipe surface outside the weld, which are caused accidentally by electrical arcs
between the electrode, electrode holder, welding cable or welding cable round and the
pipe shall be removed by grinding in accordance with a procedure approved by the
COMPANY and the repair checked by ultrasonic, magnetic particle or dyepenetrant
tests which the COMPANY feels necessary. The pipe wall thickness after grinding
shall not be less than the minimum thickness limit permitted for the pipe. Repair of arc
strikes by welding is prohibited.
The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc.
These requirements apply not only to completed welds but also to the bare strip at least
so wide as to allow full skid examination at both ends of the pipe to allow a good
ultrasonic inspection when it is required.
11.0 HEAT TREATMENT
11.1 Preheating
a) Preheating requirements for the various materials shall be as per the welding
specification chart attached along with other project data sheets.
b) Preheating shall be performed using resistance or induction /heating methods.

Preheating by gas burners is allowed only in exceptional cases with the
permission of the COMPANY.
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c) Preheating shall extend uniformly to at least three times the thickness of the
joint, but not less than 50 mm, on both sides of the weld.
d) Preheating temperature shall be maintained over the whole length of the joint
during welding. Temperature indicating crayons or other temperature indicating

devices shall be provided by the CONTRACTOR to check the temperature.
11.2 Post weld Heat Treatment
a) Post weld heat treatment, wherever required for joints between pipes and
fittings, pipe body and supports shall be carried out by the CONTRACTOR at
his expense as per the relevant specifications, applicable standards and the
instructions of the COMPANY.
b) The heat treatment of welded joints shall be carried out as per the requirements
laid down in ANSI B31.8 and other special requirements mentioned in welding
specification chart.
c) The CONTRACTOR shall submit for the approval of the COMPANY, well
before carrying out actual heat treatments the details of the post weld heat
treatment procedure, as per Exhibit `B’ attached, that he proposes to adopt for
each of the materials/assembly/part involved.
d) Post weld heat treatment shall be done in a furnace or by using an electric

resistance or induction heating equipment, as decided by the COMPANY.
e) While carrying out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the portion
being heat-treated. Care shall be taken to ensure that width of heated band over
which specified post weld heat treatment temperature is attained is at least as
that specified in the relevant applicable standards/codes.
f) The width of the heated band centered on the weld shall at least be equal to the
width of weld plus 2” (50 mm). The temperature gradient shall be such that the
length of the material on each side of the weld, at a temperature exceeding half
the heat treatment temperature, is at least 2.5 rt where r is the bore radius and t
is the pipe thickness at the weld.
g) Throughout the cycle of heat treatment, the portion outside the heat band shall
be suitably wrapped under insulation so as to avoid any harmful temperature
gradient at the exposed surface of pipe. For this purpose temperature at the
exposed surface of the pipe shall not be allowed to exceed 4000 C.
h) The temperature attained by the portion under heat treatment shall be recorded
by means of thermocouple pyrometers. Adequate number of thermocouples
shall be attached to the pipe directly at equally spaced locations along the
periphery of the pipe joint. The minimum number of thermocouples attached
per joint shall be 2 up to 10” dia and 3 for 12” dia and above. However, the
COMPANY can increase the required minimum number of thermocouples to be
attached if found necessary.
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i) Automatic temperature recorders, which have been suitably calibrated, shall be
employed. The calibration chart of each recorder shall be submitted to the
COMPANY prior to starting the heat treatment operation and its approval shall
be obtained.
j) Immediately on completion of the heat treatment, the post weld heat treatment
charts/records along with the hardness test results on the weld joints (whenever
required as per the welding specification chart) shall be submitted to
COMPANY for its approval.
k) Each joint shall bear an identification number, which shall be maintained in the
piping sketch to be prepared by the CONTRACTOR. The joint identification
number shall appear on the corresponding post weld heat treatment charts. The
same identification numbers shall also be followed for identification of
corresponding radiographic films. The chart containing the identification
number and the piping sketch shall be submitted to the COMPANY in suitable
folders.
l) Vickers hardness/Brinnel hardness of the heat affected zone as well as of the

weld metal, after heat treatment shall be measured using a suitable hardness
tester and shall not exceed the maximum hardness specified in the welding
specification chart. The weld joint shall be subjected to reheat treatment, when
hardness measured exceeds the specified limit, at the CONTRACTOR’S own
expense.
m) The CONTRACTOR shall arrange for the hardness testing and shall maintain
the records of all the joints tested. These records shall be checked by the plant
COMPANY’S inspector.
12.0 INSPECTION & TESTING
12.1 General
a) The COMPANY’S Inspector shall have free access to all the concerned areas,
where the actual work is being performed. The CONTRACTOR shall also
afford the COMPANY’S inspector all means and facilities necessary to carry
out inspection.
b) The COMPANY is entitled to depute its own inspector to the shop or field
where pre-fabrication and erection of pipelines are being done, with (but not
limited to) the following objectives:
i) To check the conformance to relevant standards and suitability of

various welding equipment and the welding performance.
ii) To supervise the welding procedure qualification.
iii) To supervise the welders’ performance qualification.
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iv) To check whether shop/field welding being executed is in conformity
with the relevant specifications and codes of practice followed in pipe
construction.
c) CONTRACTOR shall intimate sufficiently in advance the commencement of

the qualification tests, welding works and acceptance tests, to enable the
COMPANY’S inspector to be present to supervise them.
12.2 Welding Procedure Qualification
a) Welding procedure qualification shall be carried out in accordance with the

relevant requirements of API 1104 latest edition or other applicable codes and
other job requirements by the CONTRACTOR at his expense. The
CONTRACTOR shall submit the welding procedure specifications in format as
per Exhibit-C (attached) immediately after the receipt of the order.
b) COMPANY’S inspector will review, check and approve the welding procedure
submitted and shall release the procedure for procedure qualification tests. The
procedure qualification test shall be carried out by the CONTRACTOR under
field conditions at his own expense. A complete set of the test results in format
as per Exhibit-C (attached) shall be submitted to the COMPANY’S Inspector
for approval immediately after completing the procedure qualification test and
at least 2 weeks before the commencement of actual work. Standard tests as
specified in the code shall be carried out in all cases. In addition to these tests,
other tests like Ultrasonic examination, radiography, macro/micro examination,
hardness tests, dye penetrant examination, charpy v-notch etc. shall be carried
out on the specimens. It shall be the responsibility of the CONTRACTOR to
carry out all the tests required to the satisfaction of the COMPANY’S Inspector.
The destructive testing of welded joints shall be as per Annexure – 1.
12.3 Welder’s Qualification
a) Welders shall be qualified in accordance with the API 1104 and other applicable
specifications by the CONTRACTOR at his expense. The butt weld test pieces
of the qualification test shall meet the NDT requirements specified in Clause
12.5 and Annexure-2/3/4 (as applicable) of this specification. The
COMPANY’S inspector shall witness the test and certify the qualification of
each welder separately. Only those welders who have been approved by the
COMPANY’S inspector shall be employed for welding. CONTRACTOR shall
submit the welder qualification test reports in the standard format as shown in
Exhibit – D and obtain express approval, before commencement of the work. It
shall be the responsibility of CONTRACTOR to carry out qualification tests of
welders.
b) The welders shall always have in their possession the identification card as
shown in Exhibit-E and shall produce it on demand by the COMPANY’S
Inspector. It shall be the responsibility of the CONTRACTOR to issue the
identity cards after the COMPANY has duly certified it.
c) No welder shall be permitted to work without the possession of identity card.
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d) If a welder is found to perform a type of welding or in a position for which he is
not qualified, he shall be debarred from doing any further work. All welds
performed by an unqualified welder shall be cut and redone by a qualified
welder at the expense of the CONTRACTOR.
12.4 Visual Inspection
COMPANY shall carry out inspection of all welds as per the latest editions of the
applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity, shrinkage,
cracks, under-cuts, dimensions, surface porosity and other surface defects.
Undercutting adjacent to the completed weld shall not exceed the limits specified in the
applicable standard / code.
12.5 NON DESTRUCTIVE EXAMINATION
12.5.1 The non-destructive examination of one hundred percent (100%) girth welds shall be
carried out.
The non-destructive examination shall mainly consist of examination using automatic

ultrasonic testing (AUT) as detailed in Annexure-3. This shall be applicable for all
welds made by automatic GMAW with narrow bevels (Spread I, II). Welds made with
API bevels may be examined either by radiography or automatic ultrasonic
examination. When radiography is used the provisions stated in para 12.5.2 shall be
applicable. Welds shall meet the standards of acceptability as set forth in API 1104 and
as well as the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the Automatic ultrasonic
examination of work covered by the specification at his expense. The CONTRACTOR
shall furnish all the reports to the COMPANY, immediately after examination, together
with the corresponding interpretation reports on approved format. The details of the
AUT reports along with the joint identification number shall be duly entered in a
register and signed by the CONTRACTOR and submitted to the COMPANY for
approval. The COMPANY will review all the Automatic ultrasonic examination
records of welds and inform the CONTRACTOR regarding unacceptable welds. The
decision of the COMPANY shall be final and binding in this regard.
All the requirements mentioned in the specification shall be arranged and executed by
the CONTRACTOR through his own resources. In addition, radiographic examination
shall be required in the following cases as per Annexure – 4 of this Specification.
a) On the first 100 welded joints corresponding to each automatic GTAW/GMAW

welding procedure used.
b) When welds are repaired.
c) When in the opinion of COMPANY, radographic inspection is required to

confirm or clarify defects indicated by ultrasonic examination.
d) Welding of transition piece of pipe.
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In addition, radiographic inspection may be required for certain critical welds of the
pipeline (i.e. tie-ins, welding of valves, flanges) randomly selected at COMPANY’s
discretion. All fillet and groove welds other than those AUT examined shall be
subjected to dye penetrant/ MP inspection and examined by manual ultrasonic testing.
The non-destructive test system used for inspecting welds must by approved by the
COMPANY.
12.5.2 Tie in and other welds having API bevel may be examined by radiography or automatic
ultrasonic examination. When radiography is used the provisions stated in this para
shall be applicable.
Welds shall meet the standards of acceptability as set forth in API 1104 and as well as
the requirements laid in subsequent paragraphs.
The CONTRACTOR shall make all the arrangements for the radiographic examination
of work covered by the specification at his expense.
The COMPANY will review all the radiographs of welds and inform the
CONTRACTOR regarding unacceptable welds. The decision of the COMPANY shall
be final and binding in this regard.
All the requirements mentioned in the specification shall be arranged and executed by
the CONTRACTOR through his own resources. In addition, ultrasonic inspection is
required in the following cases as per Annexure – 2 of this Specification.
a) On the first 10 welded joints corresponding to each automatic (GTAW/GMAW)

welding procedure used.
b) When welds are repaired.
c) When in the opinion of COMPANY, ultrasonic inspection is required to

confirm or clarify defects indicated by radiography.
In addition, ultrasonic inspection may be required for certain critical welds of the
pipeline (i.e. tie-ins, welding of valves, flanges) randomly selected at COMPANY’s
discretion. All fillet and groove welds other than those radiographed shall be subjected
to dye penetrant/ MP inspection. The non-destructive test system used for inspecting
welds must by approved by the COMPANY.
12.5.3 Acceptance Criteria
Weld quality as judged on the basis of the acceptability criteria mentioned below:
i) Any weld, which as a result of radiographic and/or ultrasonic examination in the

opinion of COMPANY exhibits imperfections greater than the limits, stated in
API 1104 latest edition or as superseded in this article shall be considered
defective and shall so be marked with an identification point marker.
ii) In addition to the API 1104 requirements, the welds containing cracks including
crater cracks regardless of size or location are unacceptable.
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Suitable records shall be maintained by the CONTRACTOR as desired by the
COMPANY on the day to day work done on welding radiography, ultrasonic testing.
The CONTRACTOR shall present the records to the COMPANY on day-to-day basis
and whenever demanded, for approval.
12.6 Destructive Testing
Welds cut out for defects for any reason may be subjected to destructive testing. The re-
execution of welds shall be carried out by the CONTRACTOR at his own expense. If
the results are unsatisfactory, welding operations shall be suspended and may not be
restarted until the causes have been identified and the CONTRACTOR has adopted
measures, which guarantee acceptable results. If it is necessary in the COMPANY’s
opinion the procedure shall be re-qualified. The weld joint represented by
unsatisfactory welds shall stand rejected unless investigation proves otherwise.
13.0 REPAIRS OF WELDS
13.1 With the prior permission of COMPANY welds, which do not comply with the
standards of acceptability, shall be repaired or the joint cut out and re-welded.
A separate welding procedure specification sheet shall be formulated and qualified by

CONTRACTOR for repair welds simulating the proposed repair to be carried out.
Separate procedures are required to be qualified for (a) through thickness repair (b)
external repair and (c) internal repair. Welders shall be qualified in advance for repairs.
The root pass, for repairs opening the root, shall be replaced by the vertical uphill
technique. The procedure shall be proven by satisfactory procedure test to API-1104
including the special requirements of the specification, and shall also be subjected to
metallographic examination, hardness surveys and Charpy tests to determine the effects
of repair welding on the associated structure.
The repair shall be subjected, as a minimum requirement to the same testing and
inspection requirements as the original weld. Re-radiography of the repaired area shall
be carried out. In addition, a minimum of 6” weld on either side of the repaired area
shall be re-radiographed. A 100% ultrasonic test shall be done at the repaired area
externally. Any repaired area that is wide, irregular or rough shall be rejected and a full
cut out shall be done. Single pass repairs shall be subjected to 100 % DP/MPI tests.
Repairs are limited to a maximum of 30% of the weld length. Not more than two
repairs are permitted on the same location. All repairs shall be carried out the day after
initial radiography or earlier. A full report of all repairs made shall be submitted every
day to the COMPANY.
13.2 Weld Rejected by Accumulation of Defects
Where a weld is rejected by the accumulation of defect clause, as defined by API-1104

and this specification, repairs within these limitations are permitted. Defects in the
filling and capping passes shall be repaired preferentially.
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The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that ANNEXURE - 1
1.0 DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS

1.1 Preparation
Having passed the visual and the non-destructive inspection, the test weld shall be
subjected to mechanical test.
After satisfactory completion of all visual and non-destructive testing the procedure test
weld shall be set-aside for a period not less than 24 hours. No further work on the test
weld and no cutting of test specimens from the weld shall be performed until a period
of at least 24 hours has expired.
Weld specimens shall be taken from the positions indicated in fig.1& 1A of this
specification from areas as free from defects as possible; for this reason it is necessary
to take the previous non-destructive tests into account. The minimum number of tests
to be carried out is given in Table - 1 of this specification.
The test shall be carried out at laboratories approved by the COMPANY. The
specimens shall be prepared in accordance with the figures given in the paragraphs that
refer to the individual test.
1.2 TENSILE STRENGTH
Specimens shall be taken from the position indicated in fig. 1 & 1A of this
specification. Two ISO type specimens and two API-type specimens shall be taken.
The ISO test specimens are shown in fig. 2 of this specification.
1.2.1 Method
The test shall be carried out in accordance with ISO 375.
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The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that TABLE 1
PIPE
NUMBER OF SPECIMENS
SIZE,
OUT R
SIDE TENSILE O
DIAM O
NICK
ETER T FACE IMPAC
BREA SIDE BEND MACRO HARDNESS TOTAL
INCHE B BEND T
API ISO K
S E
N
D
WALL THICKNESS ½ INCH (12.7 mm) AND UNDER

UNDE
0 0 2 2 0 0 0 0 0 4
R2
2 TO
4½
0 0 2 2 0 0 0 0 0 4
INCLU
DING
OVER
4½
LESS 2 0 2 2 2 0 2 2 12 24
THAN
12¾
12¾
AND 2 2 4 4 4 0 2 2 24 44
OVER
WALL THICKNESS OVER ½ INCH (12.7 mm)

4½
AND
0 2 0 0 0 2 0 0 0 4
SMAL
LER
OVER
4½
LESS 2 0 2 2 2 0 2 2 12 24
THAN
12¾
12¾
AND 2 2 4 0 0 8 2 2 24 44
OVER
1.3 NICK-BREAK TEST
1.3.1 Preparation
Specification for nick-break test with notches thus worked can break in the base metal,
instead of in the fusion zone; therefore an alternative test piece may be used after
authorization by the COMPANY with a notch cut in the reinforcement of outside weld
bead to a maximum depth of 1.5mm, measured from the surface of the weld bead.
1.4 MACROSCOPIC INSPECTION
1.4.1 Preparation
Specimens shall be taken from the positions indicated in Fig. 1 of this specification and
shall be prepared in accordance with ASTM E2 and E3.
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The width of the macro section has to be at least three times the width of the weld. The
section is to be prepared by grinding and polishing and etched to clearly reveal the weld
metal and heat affected zone.
1.4.2 Method
Specimens shall be carefully examined under the microscope, with a magnification of at

least 25 times (25:1). The COMPANY may ask for a macrograph with 5 times (5:1)
magnification, for DOCUMENTATION purposes.
1.4.3 Requirements
Under macroscopic examination, the welded joints shall show good penetration and
fusion, without any defect exceeding the limits stated in the evaluation criteria of the
nick bream test.
1.5 HARDNESS TEST

1.5.1 Preparation
The prepared macro section is to be used for hardness testing using the vickers method
with 10 kg load indentations are to be made along traverses each approximately 1 mm
below the surface at both side of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses are to
be made. The HAZ indentations are to be made along the traverses for approximately
0.5mm each into unaffected material, and starting as close to the fusion line as possible.
One indentation at each side of the weld along each traverse has to be made on parent
metal. Reference is made to Fig. 3 of this specification. The indentations are to be
made in the adjacent region as well as on the opposite side of the macro section along
the specified traverses.
1.5.2 Method
The test shall be carried out in accordance with recommendation ISO R81, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO R
146 and using a diamond pyramid penetrator set at 2.37 rad (136") with a load of 10 kg.
1.5.3 Requirements
Hardness value shall not exceed the limit specified in welding specification chart. In
case of a single reading strictly (+10HV) higher than the specified limit, further
indentations shall be made to check if the high value was an isolated case.
All the hardness values contained from the heat-affected zone shall not exceed 100 HV
with respect to the average hardness of the values obtained for the base metal. If these
additional tests give hardness within the specification limit the slightly higher value
may be accepted.
1.6 CHARPY V-NOTCH IMPACT TEST

1.6.1 Specimens shall be taken from the position indicated in Fig. 1 of this specification. The
test specimens will be prepared in accordance with ISO R 148. Charpy V-Notch
specimens shall have dimensions as given in Fig. 3 of the specification. Three test
specimens shall be taken from each sample and they shall be cut and worked so that
their length is transversal and perpendicular to the weld bead with the notch position as
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shown in Fig. 4 of this specification. The notch shall be perpendicular to the roller
surface. The test specimen width shall depend upon the pipe wall nominal thickness as
per the following table:
Nominal wall thickness Test specimen width

(mm) ( mm)
Over 12 10
Over 9.5 and up to 12 7.5
From 7 up to 9.5 5
Less than 7 2.5
1.6.2 Test Method

The test shall be carried out as indicated in ISO R 148 “Beam Impact Test V-Notch”.
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall then be placed in the testing machine
and broken within 5 seconds of their removal from the bath. The test temperature shall
be as mentioned in welding specification chart.
1.6.3 Requirements (Note 1)
The impact energy shall be:
Test Specimen Average of three Minimum single value

in mm specimens (Note 2) Joules (Note 1) Joules
(Min.)
10.0 27.0 22.0
7.5 21.5 17.5
5.0 18.5 15.0
2.5 10.0 8.0
Note:
(1) These values are specified for resistance to brittle fracture only. Where
additional requirements are specified in project data sheet (Ex. pipeline
materials with arrest properties i.e. a higher upper shelf charpy V energy for
resistance against propagating ductile fractures) the same shall be followed.
(2) Only one value is permitted to be lower than average value up to the value
specified.
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1.7 BEND TEST REQUIREMENTS
The Bend test Specimens shall be made and tested as per the requirements of API 11-4
Nineteenth Edition, September 1999. However, the dimensions of the Jig for guided
bend test in Fig. 9 shall be modified as specified below:
Radius of the Plunger `A' = 2t

Radius of the die. `B' = 3t + 1.6 mm
Width of the die. `C' = 50.8
The acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API 1104
Nineteenth edition, September 1999.
Note: t = thickness of specimen
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ANNEXURE - 2
1.0 ULTRASONIC INSPECTION

In addition the radiographic inspection, ultrasonic inspection is required as per

conditions listed in paragraph 12.5 of this specification. This section concerns manual
ultrasonic inspection. However ultrasonic inspection by automatic equipment may be
used if approved by the COMPANY.
1.1 GENERAL:
The CONTRACTOR who carries out the ultrasonic inspections shall have sufficient no.
of qualified personnel, equipment and instruments at his disposal to be able to effect the
tests without hindering or delaying the pipeline assembly operations.
The CONTRACTOR appointed to carry out ultrasonic inspections shall supply all the
instruments necessary for their execution on site.
1.2 SPECIFICATION FOR ULTRASONIC TESTING PROCEDURE

QUALIFICATION
Before work begins, the CONTRACTOR shall present a specification describing the
proposed U.T. procedure qualification.
This specification shall state, all the parameters described in API 1104 and the
following information:
a) Type of U.T. equipment used;
b) Type and dimensions of transducers
c) Frequency range
d) Details for calibration
e) Coupling medium
f) Inspection technique
g) Record details
h) Reference to the welding procedure where it is intended to adopt the
specification
I) Temperature range of the joints to be inspected.
1.3 QUALIFICATION OF ULTRASONIC INSPECTION PROCEDURE

The ultrasonic inspection procedure shall be approved by the COMPANY. Before
inspection begins, the COMPANY may require the qualification test of the ultrasonic
inspection procedure. This specification test consists in testing (under normal operating
conditions) some CONTRACTOR welds made according to the same production
procedure, where there are typical defects the test intends to detect.
This test shall be conducted in the presence of the COMPANY.
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1.4 TEST PROCEDURE
Circumferential welds shall be inspected from both sides using angle probes.
The surface with which the probe comes into contact shall be free of metal spatter, dirt,
iron oxide, and scales of any type; therefore it shall be necessary to clean a strip at least
50 mm wide on both sides of the weld with steel-wire brushes and anyhow the cleaned
strip must be at least wide enough to allow one and a half skip examination.
If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam transducer
in order to check whether any manufacturing defects are present which could have
interfered with the ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following:
a) Ultrasonic equipment and coupling medium
b) Sample sections for calibration of instruments
c) Equipment for cleaning of surface to be examined
d) Rules calibrated in centimeters for exact location of the position of defects.
The characteristics of the above listed instruments and equipment shall guarantee:
a) That the required standards of the inspection procedure, as previously
established an approved by the COMPANY, are satisfied.
b) Continuous operation
All the instruments and equipment shall be approved by the COMPANY before being
used. The COMPANY has the authority to reject any item that is considered
unsuitable. The decision of the COMPANY is final. The CONTRACTOR appointed
to carry out ultrasonic inspections shall also ensure the operational efficiency and
maintenance of the instruments and equipment, and shall immediately substitute any
item rejected by the COMPANY.
All the instruments and equipment necessary for carrying out ultrasonic inspection on
site shall satisfy the requirements laid down by the public boards of institutions that
regulate `safety at work'.
1.5 ULTRASONIC INSTRUMENTS

The ultrasonic instrument:
a) shall be pulse echo type, able to generate, receive and display, on the screen a
Cathode Ray Tube (CRT), pulse at frequencies between 1 and 6 MHz. The
useful part of the CRT screen shall be at least 70mm wide and at least 50mm
high.
shall have variable amplification, with steps of 1 or 2 dB over a range of a least
60 dB.
b) the regulation control shall be accurate to within ±1 dB and this accuracy shall
be certified by the instrument manufacturer.
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c) may be powered by a battery or an electric generator. In the first case, the
autonomy of operation (endurance) of the instrument shall be sufficient to carry
on working without frequent interruptions, and the instrument shall be equipped
with an automatic switch which switches if off when the battery runs down; in
the second case, there must be a voltage stabilising device with a tolerance of ±2
Volts.
1.6 PROBES
The probes used shall have dimensions, frequencies, and a refraction angle suited to the
type of steel, the diameter, and the thickness of the pipeline and to the joint design.
1.7 REFERENCE SAMPLE PIECES

The efficiency of the equipment used, the effective refraction angle of the probe, and
the beam output point, shall be checked using a V1 and V2 sample block, IIW type or
the calibration block ASTM E-428.
For manual ultrasonic testing and automated ultrasonic testing the reference sample
pieces shall be as described in API 1104, Nineteenth Edition, para 11.4.5.
1.8 CALIBRATION
The calibration, qualification of the testing procedure shall be done as provided in API
1104.
1.9 REGULATION OF AMPLIFICATION DURING PRODUCTION TESTING

Scanning sensitivity shall be as provided in API 1104 para 11.4.7.2 &11.4.7.3.
1.10 QUALIFICATION OF ULTRASONIC TESTING OPERATORS

Before the inspection begins or during the same inspection, the COMPANY may
require a qualification test for the ultrasonic equipment operators.
The operators shall be fully qualified as per a recognized standard (ASME Sec V or
equivalent) and they shall have as minimum level II as described in para 11.4.3,API
1104,Ninteenth Edition. The operators shall be able to:
a) calibrate the equipment;
b) perform an operational test under production conditions;
c) interpret the screen picture;
d) evaluate the size and location of reflectors
e) interpret the type of defects detected
The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.
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1.11 EVALUATION OF INDICATIONS GIVEN BY ULTRASONIC TESTS
Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference amplifications
and the probe shall be moved until maximum response is obtained, paying attention all
the time to the probe-tube coupling.

If, under these conditions, the height of the defect echo is equal to or greater than that
of the reference echo, the defect shall be evaluated according to clause 12.5 of this
specification. If the defect has also been detected by the radiographic and/or visual
examination, the dimensions shall be judged according to the type of examination
which detects the greater defect. Returns that are less than 50% of the reference echo
will not be considered. If returns are above 50% but lower than 100% of the reference
echo, and if the operator has good reasons to suspect that the returns are caused by
unfavorably oriented cracks, he shall inform the COMPANY. Moreover, when there is
a defect to be repaired, such defect shall be removed for a length corresponding to the
one where no more return echo is given.
1.12 OTHER EQUIPMENT

The use of rules calibrated in centimetres, attached if possible to the probe, for the
precise location of the position of welding defects, is recommended. Defect location is
effected by measuring the projection distance between the probe output and the
reflecting surface.
The operators carrying out the tests shall have, besides the probing instrument, tools for
cleaning the pipe surface (files, brushes, etc.) as well as the coupling liquid or paste
appropriate for the temperature of the section to be examined.
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ANNEXURE-3
AUTOMATIC ULTRASONIC TESTING

1.0 INTRODUCTION
2.0 REFERENCE DOCUMENTS
3.0 APPROVED AGENCIES
4.0 AUT SYSTEM
5.0 COUPLING
6.0 SEARCH UNITS
7.0 CALIBRATIONS
8.0 PROCEDURE
9.0 TRAINING AND QUALIFICATION
10.0 FIELD EXAMINATIONS AND REPORTING
11.0 INTERPRETATION OF RESULTS
12.0 ACCEPTANCE CRITERIA
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1.0 INTRODUCTION:
The specification shall be applicable for automatic ultrasonic testing system (AUT)
suitable for pipeline girth welds. The system shall be based on focused pulse echo,
tandem or through transmission methods enhanced with mapping image and augmented
by time of flight diffraction (TOFD) technique.
2.0 REFERENCE DOCUMENTS:
ASTM E 1961-98 Standard practice for Mechanized Ultrasonic Examination of Girth

welds using zonal discrimination with focused search Units.
Appendix-E, Automated Ultrasonic Girth weld testing, 0S-F-101, Submarine Pipeline

Systems, January 2000.
The inspection system shall meet and exceed the requirements of ASTM E 1961-98.
3.0 APPROVED AGENCIES:
Following agencies for Automatic welding Systems are acceptable:

a) RTD Quality services, Rotterdam, Netherlands
b) SHAW pipeline services, Canada
In case bidder proposes to employ any other agency, the proposed agency shall meet
the qualification criteria listed below and shall submit necessary documentation to
establish meeting the criteria. The detailed system description and procedure shall be
submitted for company evaluation/ approval.
Automatic ultrasonic testing systems and agencies who have proven track record and
have done a single project of diameter 36” or above and minimum length of 50 km and
also have inspected a cumulative length of 500 km or above on large diameter Pipe
lines, in the last ten years only shall be accepted. The agency should have been
approved by reputed inspection agencies. The track record shall be submitted to the
company for approval prior to engagement.
4.0 AUT SYSTEM
The system shall meet and exceed the requirements of ASTM E1961-98.
The system shall provide an adequate number of examination channels to ensure the
complete volumetric examination of the weld thru the thickness in one circumferential
scan.
The evaluation zones should be of maximum 2mm height. The instrument linearity
should be such that the accuracy of any indicated is with in 5%.
Each examination channel should be selective for pulse-echo or through transmission

mode gate position and length for a minimum of two gates and gain.
TOFD techniques & B Scan mapping should be available to improve characterization.

Recording thresholds should be selectable to display signals between 0 and 100% of
full screen height for simple amplitude and transit time recording and it should be from
0 to 100% for B scan or mapping type recording of data. Two recordable signals out
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put per gate should be available being either analog or digital and representative of
signal height and time of flight. Measuring distance accuracy of circumferential weld
shall be with in 1 cm from 0(zero) position.
Electronic noise shall be lower than acoustical noise in all channels for the probes and
sensitivities to be used during inspection. The signal to noise ratio for each channel
during examination shall be atleast ≥ 20 db for shear waved probes.
5.0 COUPLING:
The coupling shall be obtained by using a medium suitable for the purpose. It shall be
suitable for the temperature used. No residue shall remain on the pipe surface. A
method should be employed to determine that constant coupling is achieved during
examinations. An examination of the test piece with its surface wiped dry should
produce a record showing an absence of the couplant recording signal.
6.0 SEARCH UNITS:
The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961-
98.
7.0 CALIBRATIONS:
Reference standards shall be manufactured from a section of unflawed project specific

line pipe supplied by pipeline contractor. The agency shall then submit the reference
standard design to the company before manufacturing. No design changes in the
reference standard shall be made without the prior approval. Annexure A3 of the
standard ASTM E1961-98 provides an example of typical reference standard.
The system shall be optimized and calibrated as stated in Para 7.0 & 8.0 of ASTM E
1961-98. Static and Dynamic calibration shall be done and the approved procedure
shall clearly state the gain setting fixed for each channel.
The reference standard should be used to verify the scanning sensitivity at the start of
each shift and thereafter at intervals not exceeding 2 hrs. or ten welds.
A recalibration shall be carried out if

The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration.
After a weld repair
After equipment breakdown
In case the calibration differs from the initial setting, outside the given tolerances, the
applicable probe(s) and coupling shall be checked. If the calibration has to be changed,
the welds before this calibration upto the previous calibration will be re-examined.
The reference standard design for calibration shall be approved separately. The
procedure for calibration and verification shall be same as given above.
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8.0 PROCEDURE:
A detailed automated Ultrasonic examination procedure shall be prepared and qualified

for each wall thickness and joint geometry to be examined prior to the start of any NDT
work. Repair procedure shall be separately qualified for each joint geometry All the
requirements of ASTM E1961-98 should be met. The procedure, as a minimum shall

include
- Functional description of equipment
- Reference standards and guidelines controlling equipment maintenance
- Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics,

Hard & Software for recording processing, Display presentation and storage of
inspection data
- Transducer configuration(s), characteristics types coverage.
- Number of examination zones for each wall thickness to be examined.
- Gate settings
- Equipment settings
- Description of calibration blocks including type, size and location of calibration

reflectors
- Calibration intervals
- Calibration records
- Static and dynamic calibration procedure
- Identification of inspection starting point scanning direction and indication of

length inspected.
- Method for scanner alignment and maintenance of alignment
- Allowed temperature range
- Couplant coupling and coupling control and channels provided to indicate lack
of coupling and method to ensure constant coupling
- Transducer and over all functional checks
- Height and length sizing methodology
- Surface condition and preparation
- Description of inspection work
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- Acceptance criteria and instructions for reporting including example of recorder
chart and forms to be used.
- A table indicating corresponding channel no., probe, type, location of reflector,

probe coupling etc.

8.1 Setting of inspection gates
8.1.1 Pulse echo and tandem channels
With each transducer positioned for the peak signal response from the calibration
reflector the detection gates are to be set. The gate shall start 2-6mm (allowance for
width of heat affected zone) before the theoretical weld bevel preparation. The gate
ends shall be after the theoretical weld centerline. All gates will be programmed to
record amplitude and/or transit distance information. The length of the transit distance
in the root channel will be extended to enable root penetration registration.
8.1.2 Mapping channels
The mapping gates in the body of the weld shall start 2-6mm (allowance for width of
heat affected zone) before the theoretical weld bevel preparation. The gate length will
be extended to enable cap reinforcement registration. The mapping gates in the root
will be set identical to the pulse echo transit distance channels to enable the registration
of the root penetration.
8.1.3 TOFD channel
The TOFD gate start will be set 1 µSec before the arrival of the lateral wave and should
extend up to the first backwall echo, to achieve full cover of wall thickness.
Note: The gate settings may be altered if geometry indications dictate.
8.1.4 Sensitivity settings
With each transducer positioned for the peak signal response from the calibration
reflector (flat bottom holes) the detection gates are to be set. In this position the probe
holder is fixed to the probe frame. The equipment sensitivity (echo amplitude) for all
inspection channels shall be set at 80% Full Screen height.
Mapping channels in the body of the weld will be used to detect the presence of
porosity, and in addition to identify the position of the weld cap reinforcement for
pattern recognition purpose. The sensitivity as a minimum is equal to the related pulse
echo channels, increased with additional gain to ensure proper detection.
Mapping channels in the root will be used to identify the position of the root
penetration for pattern recognition purpose. The sensitivity as a minimum shall be
equal to the related pulse echo channels, increased with additional gain to ensure proper
detection.
The lateral wave of the TOFD channel sensitivity is set at 80% FSH.
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9.0 Training and qualification:
1. All owners’ inspectors shall be imparted training at the contractors cost. The
inspector shall be provided complete awareness & knowledge regarding the

equipment, limitations, capabilities complete range, method of operation,

calibration, scanning, including development of suitable procedure, training on
variables effecting the system performance and interpretation of results.
2. The ultrasonic lead operator performing the examination shall be qualified in

accordance with the company’s written practice and in accordance ASNT-
SNT-TC-1A 1996 and EN 473 Level II.
have experience in multichannel UT equipment
be trained in using mechanized UT manipulators.
10.0 Field examinations & Reporting:
All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a
minimum.
11.0 Interpretation of results:
11.1 General
With the transit distance measurements and with the information from the mapping and
TOFD channels visible on the result presentation, indications shall be judged whether
they are from the weld geometry or defects. The coupling channels will check for
coupling loss, in case of coupling loss a rescan shall be carried out.
11.2 Inspection result
The inspection result should be evaluated and/or reported as follows:
Welds shall be evaluated using both the pulse echo and TOFD criteria shown below.
This shall be performed parallelly, and rejection against either of these criteria shall be
cause for rejection of the weld. The exceptions to this are described in the following
notes;
1. All indications in the pulse echo channels should be evaluated which exceed the
threshold level of 20% FSH.
2. Defect length shall be measured for the pulse echo channels from the point
where the signal exceeds 20% FSH to the point the signal falls below. The
largest height assessed with TOFD or the greatest measured amplitude with
pulse echo shall be assumed to apply over the whole defect length .
3. If the indication cannot be resolved by TOFD (i.e. the upper and lower flaw
diffraction tips cannot be separately distinguished) then no measurement can be
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made to determine the defect height. In this case, the signal from the pulse echo
channels will be solely used to determine that particular area of the scan.
4. Defects shall be assessed for interaction as follows;

Horizontal interaction
If the distance between two adjacent defects is less than the length of the
smaller of the two defects, then the defect shall be treated as a single defect.
Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the distance

between the two adjacent defects is less then the height of the shorter of the two
defects, than the defect shall be treated as a single defect.(where the individual
defects cannot be resolved by TOFD, for the vertical interaction, then the
defects are assumed to interact and shall be treated as a single defect).
5. The maximum allowable accumulated defect length shall be as per the criteria
given in welding specification para 12.5.1.
12.0 Acceptance Criteria:
Weld quality shall be judged on the basis of the acceptability criteria mentioned in Para
12.5.1 of welding specification.
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ANNEXURE-4
RADIOGRAPHY
1.0 SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the
main pipeline.
The welded joints shall include the following:
i) Full girth welds on the mainline construction including double jointing of pipe,
if adopted.
ii) Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.
iii) Welds at scraper launching and receiving barrels.
iv) Terminal Piping
2.0 APPLICABLE STANDARDS

This specification shall apply in conjunction with the following (all latest edition):
i) API 1104, Standard for welding Pipelines and Related Facilities

ii) ANSI B 31.8, Code for Gas Transmission and Distribution Piping Systems.
iii) ANSI B 31.4, Code for Transportation System for Hydrocarbons, Liquid
Petroleum Gas, Anhydrous Ammonia and Alcohols.
iv) ASTM E 94, Recommended practice for Radiographic Testing
v) ASTM E 142, Standard Method for Controlling Quality of Radiographic
Testing
v) The American Society for Nondestructive Testing. Recommended Practice no.
SNT-TC-1A Supplement A.
3.0 PROCEDURE
3.1 The radiographic examination procedure to be adopted shall be submitted by the

CONTRACTOR as per Exhibit-F.
3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction
of COMPANY prior to use. It shall include but not be limited to the following
requirements:
i) Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.
ii) Type 2 and 3 films as per ASTM E-94 shall be used.
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iii) A densitometer shall be used to determine film density. The transmitted film
density shall be between 2.0 and 3.5 throughout the weld. The unexposed base
density of the film shall not exceed 0.30.
iv) Radiographic identification system and documentation for radiographic
interpretation reports and their recording system.

3.3 The CONTRACTOR shall qualify each procedure in the presence of the COMPANY
prior to use.
3.4 The procedure of radiographic examination shall produce radiographs of sufficient
density, clarity and contrast so that defects in the weld or in the pipe adjacent to the
weld, are clearly discernible.
3.5 All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately
after processing them, together with the corresponding interpretation reports on
approved format. The details of the radiographs along with the joint identification
number shall be duly entered in a register and signed by the CONTRACTOR and
submitted to the COMPANY for approval.
3.6 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each
exposure shall not exceed the values given. The minimum film overlap, in such cases,
shall be 40mm. The ellipse exposure technique may be used on nominal pipe sizes of 2
inch and smaller provided that the source of film distance used is a minimum of 12
inch.
3.7 Three copies of each acceptable radiographic procedure (as per Exhibit-F) and three
copies of radiographic qualification records, shall be supplied to COMPANY. One set
of the qualifying radiographs on the job shall be kept by the CONTRACTOR's
authorized representative to be used as a standard for the quality of production
radiographic during the job. The other two sets shall be retained by COMPANY for its
permanent record.
3.8 Three copies of the exposure charts relating to material thickness, kilo voltage, source
of film distance and exposure time shall also be made available to COMPANY by the
CONTRACTOR.
3.9 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds meet
the specified acceptance standards and (4) the nature and approximate location of
unacceptable defects observed. It must be possible to relate back to a particular butt
weld and welder on piping drawing and pipeline alignment drawing.
3.10 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting
and ending progress survey stations and (5) shall include original and three copies of
the daily radiographic record. The package shall be submitted to the COMPANY daily
when possible, but in no event later than noon of the following day.
3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark
room with controlled temperature, film viewer etc. to enable the COMPANY to
examine the radiographs.
3.12 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be subject
to the approval of the Company.
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3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the
field.
3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0 RADIATION SOURCE
4.1 Radiographic examination shall be carried out using X-radiations; radiographic

examination by Gamma rays using slow speed films may be allowed, at the discretion
of the COMPANY, in case of inaccessible joints. Radiography by Gamma ray for tie-
in-joints shall be acceptable provided D4 AGFA film or equivalent is used and the
required sensitivity obtained.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 red. (360)
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40 mm at the ends of
each film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.
5.0 LEVEL OF QUALITY

The quality level of Radiographic sensitivity required for radiographic inspection shall
be at least equivalent to the values in Figure-5.
6.0 PENETRAMETERS
6.1 The Image Quality Indicator (abreviation:IQI) shall be used for the qualification of the
welding procedure and during normal line production. Radiographic sensitivity shall be
measured with the wire image quality indicator (Penetrameter). The Penetrameter shall
be selected according to DIN-54109 or ISO-1027. For radiographs made with the
source on the outside, a Penetrameter shall be placed on each side of the film with the
smaller wire of the Penetrameter turned towards the end of the film itself. When a
complete weld is radiographed in a single exposure using a source inside the piping,
four pentrameters approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source side
and on the film side. The sensitivity obtained with IQI on the source side shall not be
less than the values shown in Fig. 5 of this specification.
The sensitivity limit may be considered to have been reached when the outline of the
IQI, its identification number and the wire of the required diameter show up clearly on
the radiograph.
The COMPANY may authorize use of types of IQI other than those planned, provided
that they conform with recognized standards and only if the CONTRACTOR is able to
demonstrate that the minimum sensitivity level required is obtained. For this
demonstration, a test shall be carried out comparing the IQI specified and the
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CONTRACTOR's to show up the identification number and other details of the
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that proposed IQI, which must be visible in the test radiograph.
7.0 FILM IDENTIFICATION MARKERS

All films shall be clearly identified by lead numbers, letters, and/or markers. The
image of the markers shall appear on the films, without interfering with the
interpretation. These markers positions shall also be marked on the part to be
radiographed and shall be maintained during radiography.
8.0 PROTECTION AND CARE OF FILM
8.1 All unexposed films shall be protected and stored properly as per the requirements of
API 1104 standard and ASTM E.94.
8.2 The exposed and unexposed film shall be protected from heat, light, dust and moisture.
Sufficient shielding shall be supplied to prevent exposure of film to damaging radiation
prior to and following the use of the film for radiographic exposure.
9.0 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the CONTRACTOR.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
in the same manner as that followed for the original welds. In addition, the repaired
weld areas shall be identified with the original identification number plus the letter R to
indicate the repair.
9.3 When evaluating repair film, radiographers shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original defect
removed.
9.4 The COMPANY will review prior to any repair of welds, all the radiographs of welds
that contain, according to the CONTRACTOR's interpretation, unacceptable defects.
The final disposition of all unacceptable welds shall be decided by the COMPANY.
10.0 QUALIFICATION OF RADIOGRAPHERS
10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API
1104 and to the full satisfaction of COMPANY.
10.2 Certification of all the radiographers, qualified as per 10.1 above, shall be furnished by
the CONTRACTOR to the COMPANY before a radiographer will be permitted to
perform production radiography. The certificate record shall include:
i) Background and Experience Record
ii) Training Course Record
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iii) Technical Examination Record
iv) Doctor's report on radiographer's Jacque 0-1 acquity eye test
v) Date of qualification
10.3 The radiographers shall be required to qualify with each radiographic procedure they
use, prior to performing the work assigned to him in accordance with the specification.
11.0 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographs shall be presented in suitable folders for
preservation along with necessary documentation.
11.2 All radiographs shall become property of the COMPANY.
12.0 EQUIPMENT AND ACCESSORIES
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for providing
the radiographic equipment, radiographic films and all the accessories for carrying out
the radiographic examination for satisfactory and timely completion of the job.
12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be
equipped with suitable mobile/stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall
be equipped with the film illuminator that has a light source of sufficient intensity and
suitably controlled to allow viewing film densities up to 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
every man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of Radioactive source of material,
CONTRACTOR shall be solely responsible for complying with all rules and
regulations set forth by Atomic Energy Commission or any other Government agencies
of India in this regard and COMPANY shall not be responsible and shall be kept
indemnified by the CONTRACTOR for default (s) of whatever nature by the
CONTRACTOR. Safety equipment as considered adequate by the COMPANY for all
necessary personnel shall be made available for use and maintained for immediate and
proper use by the CONTRACTOR.
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14.0 DISPLAY OF SAFETY INSTRUCTIONS
14.1 The safety provisions shall be brought to the notice of all concerned by display on a
notice board at prominent place at the work spot. The person responsible for the
“Safety” shall be named by the CONTRACTOR.
15.0 ENFORCEMENT OF SAFETY REGULATIONS
15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by the CONTRACTOR shall be open to inspection
by COMPANY or its representatives.
16.0 FIRST AID AND INDUSTRIAL INJURIES
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of sub-
contractors.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. Shall be posted
prominently in CONTRACTOR'S field office.
16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy
of CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.0 NO EXEMPTION
Notwithstanding the above there is nothing in these to exempt the CONTRACTOR
from the operation of any other act or rules in force.
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EXHIBIT - A
Sheet 1 of 3
ELECTRODE QUALIFICATION TEST RECORD
A: Tested at (Site name) Date:

Manufacturer’s Name :
Brand Name:
Batch Number & Size tested :
Classification & Code :
Intended for welding in position :
In combination with (if any) :
Code of Reference (used for testing) :
Special Requirements (if any) :
B: All-weld Tensile Test

Base Material used :
Pre-heat temperature :
Post weld heat treatment details :
Visual examination :
Radiographic examination results :
Tensile test results :
Identification No. U.T.S. Yield Point Elongation Remarks

1.
2.
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EXHIBIT - A
Sheet 2 of 3
C. Impact Test Results
Test Temperature : Notch in :
Type of Specimens (Charpy) : Size of Specimens :
Specimen No. Impact Average

Value
1
2
3
4
5
D. Chemical Analysis Results
Electrode Size Result :
Batch No. :
%C %S %P %Si %Mn %Cr %Ni %Mo Other
E. Fillet Weld Test Results :
Welding Positions :
Base Materials :
Size of electrode used :
Visual Inspection Results :
1)
2)
3)
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EXHIBIT - A
Sheet 3 of 3
Macro Test Results :
Fracture Test Results
Remarks :
F. Other Test Results :
1. Transverse tensile test :
In combination with :
Base material used :
Position of welding :
Preheat temperature :
Post weld heat treatment :
Radiography :
Identification No. U.T.S. Fracture in Remarks
2. Guided Bend Test :

Position Identification Root, Face or Side Rem
No. Bend arks
1
2
3
4
5
G. Any other tests :
H. Conclusions :
--------------------- -------------------- -------------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (EIL/OWNER)
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EXHIBIT - B
Sheet 1 of 1
STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION

Name of the Heat-treater :
Name of the Project : Specification Reference No.:
1. General Detail: 2. Furnace Details:

Name of the Equipment: Type of Heating : Gas/Oil/Elect.
Name of the Assembly/Part: Res./Induction Type of Heating :
Drawing No: Capacity (Size) :
Material: Maximum Temp.( C) :
Method of temp. Measurement
Atmosphere Control :
3. Heat Treatment Cycle Details :

Charging Temp. C
Rate of heating, C/Hr
Soaking Temp. C
Soaking Time, hrs.
Rate of Cooling, C/Hr.
Mode of Cooling
4. Other Details, if any :
Notes:
The following documents shall be furnished along with the specifications :
i) Material test certificates
ii) Assembly/Part Drawing.
--------------------- -------------------- -------------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (EIL/OWNER)
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EXHIBIT - C
Sheet 1 of 3
Example of record form for welding procedure qualification test
Project/Contract Contractor
Pipe and fitting material
Process
Outside
diameter
Pipe thickness
Joint design (Sketch attached)
Make Diameter Current Voltage
and type
of filler
metal
Root
Second run
Other runs
Other electrical a.c/d.c Electrode negative/Positive
characteristics
Shielding gas
Type of mixture
Flow
Shielding flux
Position
Direction of welding :
Root : Vertical up*/ Vertical down
Second run : Vertical up*/ Vertical down
Other runs : Vertical up*/ Vertical down
Number of welders :
Root
Second run
Other runs
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EXHIBIT - C
Sheet 2 of 3
Time lapse between commencement of second

run and commencement of other runs
Minimum number of runs before joint allowed
to cool
Maximum time between commencement and
completion of weld
Type of line-up clamp
Removal of clamp after run
Lowering off after run
Cleaning
Preheating
Minimum temperature C Ambient temperature C
Type of heater to be used
Interpass temperature
Minimum C Maximum C
Post weld heat treatment
Speed of travel
Test Results
State acceptable ‘non-acceptable (with
reasons) or give numerical results
Non-destructive tests
Visual
Radiograph
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EXHIBIT – C
Sheet 3 of 3
Destructive tests 1 2 3 4
Transverse tensile
Tensile strength (with units)

Fracture location
Test temperature
Macro-examination
Fillet weld fracture
Hardness survey :
Type
Hardness range :
Parent metal
Heat affected zone
weld
Charpy V-notch impact tests
Specimen location and size
Notch location
Test temperature
Results (with units)
Additional test(s) and results. e.g. chemical analysis, micro-examination, CTOD tests, Bend
tests, Nick Break test.
The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of specification.
Contractor Inspector
Position Witnessed by
Date Date
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EXHIBIT - D
Sheet 1 of 1
Example of record form for welder qualification test
Welder test certificate Test no.

Project/Contract Date
Contractor Inspector
Welder’s name
Address
Pipe material
Pipe thickness
Pipe outside diameter
Welding process Root
Fill and cap
Electrode/wire
Root Current Voltage
Second run Current Voltage
Fill and cap Current Voltage
Direction of travel Root : Vertical up*/ Vertical down
Fill and cap : Vertical up*/ Vertical down
Reason for failure

Visual
Non-destructive testing
Butt joint
Fillet weld
` Number of attempts
Comments
Accepted date/Time Signed by Contractor Signed by Inspector
* Delete as necessary
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EXHIBIT - E
Sheet 1 of 1
WELDER’S IDENTIFICATION CARD
Name :
Identification : Photograph
Date of Testing :
Valid till :
Approval of Welding :
Welding Position :
Material :
Diameter :
` Diameter range approved :
Wall thickness :
Thickness range approved :
Type of welding consumables :
Approved by : Employers’ Signature with seal
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EXHIBIT - F
Sheet 1 of 1
RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia & Thickness
6. Type of weld joint
7. Radiation Source (X-ray, iridium)
8. Type of equipment (External/Internal)
9. Intensifying screens and material
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation
source or specimen.
11. Exposure Geomety (Source focal spot size, object to film distance, radiation angle with
respect to weld and film).
12. Limit of film coverage
13. Film type and make
14. Exposure Conditions(ma.,KV,time)
15. Processing (time temperature for development stop bath or rinse, fixation, washing,
drying etc.)
16. Density
17. Sensitivity
18. Type of penetrameter
19. Essential wire to be seen on source side:
20. Essential wire accepted for film side viewing:
Approval of the COMPANY Signature of CONTRACTOR with seal
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NEW DELHI
ENGINEERS INDIA LIMITED
OF GAS
MAIN LINE FOR TRANSPORTATION
0318-6-77-0009
SPECIFICATION
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REV.
FIGURE 5. REQUIRED IQI SENSITIVITY SOURCE SIDE PENETRAMETER
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The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED.

They are merely loaned on the borrower's express agreement that

xSl dh <qykbZ ds fy,

0 23.03.06 ISSUED FOR BIDS

2.0 APPLICABLE CODES AND STANDARDS

3.0 BASE MATERIAL

4.0 WELDING CONSUMABLES

5.0 EQUIPMENT & ACCESSORIES

6.0 WELDING PROCESSES

7.0 BEVEL CLEANING AND BEVEL INSPECTION

8.0 ALIGNMENT AND SPACING

9.0 WEATHER CONDITIONS

11.0 HEAT TREATMENT

12.0 INSPECTION AND TESTING

13.0 REPAIR OF WELDS

ANNEXURE – 1 : DESTRUCTIVE TESTING

ANNEXURE – 2 : ULTRASONIC INSPECTION

ANNEXURE – 2 : AUTOMATIC ULTRASONIC TESTING

EXHIBIT-A : ELECTRODE QUALIFICATION TEST RECORD

EXHIBIT-B : STRESS RELIEF HEAT TREATMENT PROCEDURE

EXHIBIT-C : WELDING PROCEDURE QUALIFICATION TEST

EXHIBIT-D : WELDER QUALIFICATION TEST RECORD

EXHIBIT-E : WELDERS IDENTIFICATION CARD

EXHIBIT-F : RADIOGRAPHIC PROCEDURE FOR PIPE WELDING

The welded pipe joints shall include the following:

b) Attachments of castings, forgings, flanges and other supports to pipes.

c) Welded manifold headers and other sub-assemblies.

d) Welded branch connections.

e) Joints in welded / fabricated piping components.

2.0 APPLICABLE CODE AND STANDARDS

a) Code for Gas Transmission and Distribution Piping Systems,

b) Standard for welding of Pipelines and Related Facilities, API 1104.

c) Specification for welding Electrodes and Filler Materials ASME Sec. II C.

d) Non Destructive examination, ASME Sec. V.

3.0 BASE MATERIAL

a) In general carbon steel is used in this specification. The details of material

b) The welding electrodes / filler wires supplied by the CONTRACTOR shall

1. Argon gas complying with BS 4365.

2. Carbon dioxide gas complying with type 1 specified in BS 4105

content shall correspond to a dew point of -300 C or lower.

5.0 EQUIPMENT & ACCESSORIES

6.0 WELDING PROCESSES

AUTOMATIC GAS METAL ARC WELDING FROM BOTH SIDES OR WELDING

1. AUTOMATIC GAS METAL ARC WELDING FROM BOTH SIDES OR

2.a) SEMIAUTOMATIC GMAW WITH SPECIAL CONTROLLED PULSED

2.b) SEMIAUTOMATIC GMAW/ FCAW FOR FILL AND CAP RUNS

6.1.3 TIE –INS AND CROSSINGS: ANY OF THE PROCESSES SPECIFIED

6.1.4 DOUBLE JOINTING OF TWO PIPE LENGTHS USING SUBMERGED ARC

Following agencies for Automatic welding Systems are acceptable:

a) CRC-Evans Automatic Welding Systems, Houston

b) Pipe Welding Technology, Italy

6.3 A combination of different welding processes or a combination of electrodes of

7.0 BEVEL CLEANING / BEVEL INSPECTION

in no circumstances be sprung into position. Temporary attachments of any kind shall

9.0 WEATHER CONDITIONS

10.1 Root Pass

b) Position or roll welding may be permitted. Separate procedures shall be

d) Any deviations desired from the recommended welding technique and

e) Welding shall be continuous and uninterrupted during a pass.

f) On completion of each run, craters, welding irregularities, slag etc., shall be

i) Peening shall not be used.

10.2 Joint completion

11.0 HEAT TREATMENT